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Lithiumate™ Manual

index install install_hd_master

Installation - HD Master

Installation instructions for the 2CN0002E BMS master.

You MUST provide a way for the BMS to shut down the source (charger), and the load, DIRECTLY!

Otherwise, your cells are NOT PROTECTED, and will not be balanced.

BOTH GROUND PINS MUST BE WIRED TO THE SUPPLY!

back to topGood technique

We strongly recommend that you use prewired HD harnessed from Elithion.

If you choose instead to make your own harnesses, you must be able to do so with high quality assembly skills.
Unfortunately, we do not have the resources to teach all of our clients proper assembly procedures, which are essential for a successful project.
What we can do is to pass along this info to you:

back to topControl

This connector is for low power signals.

NOTE PIN NUMBERS AND TAB ORIENTATION!

Control connector
Control connector pin numbers and orientation.
# Name Type Function Notes
1 GND Gnd Ground Return for source current sensor
2 SRCCUR Inputs Source current Analog input to measure current from the source / charger
3 5V Pwr out 5 V supply To power source current sensor
4 GND 6 Gnd Bank ground Return for TX and RX for bank 6; also for shield, do not terminate shield at far end
5 TX 6 Banks Transmit out bank 6 To most positive cell in the bank; red wire
6 RX 6 Banks Receive in bank 6 To most negative cell in the bank; white wire
7 GND 4 Gnd Bank ground Return for TX and RX for bank 4; also for shield, do not terminate shield at far end
8 TX 4 Banks Transmit out bank 4 To most positive cell in the bank; red wire
9 RX 4 Banks Receive in bank 4 To most negative cell in the bank; white wire
10 GND 2 Gnd Bank ground Return for TX and RX for bank 2; also for shield, do not terminate shield at far end
11 TX 2 Banks Transmit out bank 2 To most positive cell in the bank; red wire
12 RX 2 Banks Receive in bank 2 To most negative cell in the bank; white wire
13 GND 0 Gnd Bank ground Return for TX and RX for bank 0; also for shield, do not terminate shield at far end
14 TX 0 Banks Transmit out bank 0 To most positive cell in the bank; red wire
15 RX 0 Banks Receive in bank 0 To most negative cell in the bank; white wire
16 GND Gnd Signal ground Use a separate wire from power ground, to avoid errors in analog readings.
17 CANL CAN CAN Bus low  
18 TERM CAN CAN Bus termination  
19 SOC Lin out State Of Charge analog out Analog voltage: 5 V = 100 % full, down to 0 V = empty
20 DCL Lin out Discharge Current Limit Analog voltage: 5 V = no limit, down to 0 V = no discharging current allowed.
21 GND Gnd Ground Return for load current sensor
22 LODCUR Inputs Load current Analog input to measure current to the load
23 5V Pwr out 5 V supply To power load current sensor
24 GND 7 Gnd Bank ground Return for TX and RX for bank 7; also for shield, do not terminate shield at far end
25 TX 7 Banks Transmit out bank 7 To most positive cell in the bank; red wire
26 RX 7 Banks Receive in bank 7 To most negative cell in the bank; white wire
27 GND 5 Gnd Bank ground Return for TX and RX for bank 5; also for shield, do not terminate shield at far end
28 TX 5 Banks Transmit out bank 5 To most positive cell in the bank; red wire
29 RX 5 Banks Receive in bank 5 To most negative cell in the bank; white wire
30 GND 3 Gnd Bank ground Return for TX and RX for bank 3; also for shield, do not terminate shield at far end
31 TX 3 Banks Transmit out bank 3 To most positive cell in the bank; red wire
32 RX 3 Banks Receive in bank 3 To most negative cell in the bank; white wire
33 GND 1 Gnd Bank ground Return for TX and RX for bank 1; also for shield, do not terminate shield at far end
34 TX 1 Banks Transmit out bank 1 To most positive cell in the bank; red wire
35 RX 1 Banks Receive in bank 1 To most negative cell in the bank; white wire
36 GND Gnd Signal ground Use a separate wire from power ground, to avoid errors in analog readings.
37 CANH CAN CAN Bus high  
38 TERM CAN CAN Bus termination  
39 CGND CAN CAN Bus ground  
40 CCL Lin out Charge Current Limit Analog voltage: 5 V = no limit, down to 0 V = no charging current allowed.
back to topPower

This connector is for high power signals.

NOTE PIN NUMBERS AND TAB ORIENTATION!

Power connector
Power connector pin numbers and orientation.
# Name Type Function Notes
1 FLT O.D. out Fault Open collector, polarity selectable in software. Activated in case of fault.
2 K3 O.D. out Negative contactor coil (-) Open collector
3 K2 O.D. out Positive contactor coil (-) Open collector
4 K1 O.D. out Precharge relay coil (-) Open collector
5 FAN O.D. out Low power fan drive / drive for fan relay Grounded when cooling is required
6 V+S Pwr in Power in from source The BMS is powered by voltage at either terminal (uses isolating diodes). V+L must be powered whenever the load is on, and only then. V+S must be powered whenever the source is on, and only then. For example, in a BEV or PHEV application, V+L is powered by Ignition, V+S is powered whenever the vehicle is plugged into AC power. In a HEV application, V+S is powered by the ignition. In a UPS application, V+S is powered whenever there's AC power, and V+L is powered all the time. If only one power source is possible, use V+S.
Which input powers the BMS selects which current sensor is used. If both are powered simultaneously, the current reading may double.
7 V+L Pwr in Power in from load
8 V+ Pwr out Full voltage utility supply Voltage present when BMS powered through either V+ line. May be used to power equipment such as loggers, remote controllers.
9 LLIM O.D. out Low Limit Open collector, polarity selectable in software. Activated when the most discharged cell's voltage is too low
10 HLIM O.D. out High Limit Open collector, polarity selectable in software. Activated when the most charged cell's voltage is too high.
11 PGND Gnd Power ground Use a separate wire from signal ground, to avoid errors in analog readings.
12 FAN PWM Dig out Variable Duty Cycle Pulse Width Modulation 0% DC for no cooling, up to 100% DC for full cooling
13 PGND Gnd Power ground Use a separate wire from signa ground, to avoid errors in analog readings.
14 Cont. Req. Dig in Contactor request Requests that contactors be on. For vehicle applications, connected to the Ignition line (off when ignition goes off).
15 PGND Gnd Power ground Use a separate wire from signal ground, to avoid errors in analog readings.
16 V+ Pwr out Full voltage utility supply Voltage present when BMS powered through either V+ line. May be used to power equipment such as loggers, remote controllers.

Use this circuit if driving contactors from the Lithiumate HD Master.

Contactor circuit
Contactor circuit.
back to topGrounding

BOTH GROUND PINS MUST BE WIRED TO THE SUPPLY!

This controller has 2 separate grounds.

  • Signal ground: low current, reference for digital and analog signals
  • Power ground: carries the high current for power devices: fan driver and contactor coil drivers

Both of these grounds must be connected to the negative of the low voltage supply (the 12 V nominal power supply, DC-DC converter or battery that powers the BMS), each through a separate wire.
These grounds are connected to each other on the BMS controller by a small resistor.

BMS grounding
Grounding of the BMS.

The negative of the low voltage supply (which is connected to the signal and power grounds) may or may not be connected to the earth or chassis, as required by the application.

In general, for safety reasons, the negative of the high voltage battery (the Li-Ion pack that is managed by this BMS) should not be connected to these grounds. Yet, if safety is not an issue, as far as the Elithion BMS is concerned, it is OK to do so.

BOTH GROUND PINS MUST BE WIRED TO THE SUPPLY!

back to topPower

This controller has 2 separate power inputs

  • Source: on when the power source is on, such as a battery charger
  • Load: on when the battery load is on, such as a motor driver

The BMS is on when there's voltage on either of these inputs. See the specifications for the allowable voltage range and the supply currents.

BMS power
Power to and from the HD master.

The BMS provides 2 power outputs for external devices:

  • V+: powered whenever either power input is powered, at the highest voltage of the two
  • 5V: powered at the same time, but sourcing 5 V

See the specifications for the maximum current available from these outputs.

back to topOpen Drain digital outputs

There are 7 Open Drain Outputs on the power connector

  • FLT: Fault
  • HLIM (High limit): battery unable to accept charge
  • LLIM (Low limit): battery unable to accept discharge
  • K1: precharge relay coil drive
  • K2: positive contactor coil drive
  • K3: negative contactor coil drive
  • FAN: cooling fan drive
HD open drain outputs
Open drain outputs.

Each of these outputs is either open (clamped to 42 V) or connected to the power ground, depending on the state they are reporting.

  • With a pull-up resistor to the 5 V supply, they can be used as TTL or CMOS logic outputs
  • They can drive medium power DC loads directly, such as relays
  • See the specifications for the maximum sinking current and maximum open circuit voltage for these outputs.

Note that the polarity (active open or active grounded) is programmable. See the programming instructions.

back to topSignal outputs

There are 3 linear (analog) outputs on the control connector

  • SOC (State Of Charge)
  • CCL (Charge Current Limit)
  • DCL (Discharge Current Limit)
BMS signal outputs
Signal outputs.
  • These outputs produce a voltage in the range from 0 V to 5 V, according to the state of the condition they report
  • They can drive light loads, such as the inputs of Analog to Digital converters
  • They can drive resistors of no less than 5 kOhm, such as throttle pots
  • See the specifications for their output resistance, and maximum voltage for these outputs.

There is one digital PWM output on the control connector

  • PWM (Pulse Width Modulation)
  • This is a CMOS output (0 or 5 V), with a high frequency square wave of variable duty cycle, from 0% (always at 0 V: no fan) to 100 % (always at 5 V: full fan speed)
  • It can drive a light load, such as the inputs of a power buffer
  • It cannot drive a fan directly
back to topSignal inputs

There are 3 signal inputs on the control connector

  • Source Current: a linear (analog) input
  • Load Current: a linear (analog) input
  • Contactor request: a digital input

The control connector also has ground and 5 V outputs to power current sensors.

BMS signal inputs
Signal inputs.
  • The Source Current input can be driven by a charger that puts out a linear voltage proportional to the charging current
    • This input responds to voltages in the range from 0 V to 5 V, but it is protected against voltages outside this range
  • The Contactor Request input can be driven by the 12 V ignition line in a vehicle
back to topCAN Bus

If the application includes a CAN bus, the CAN bus lines can be connected to it.

BMS CAN bus
CAN bus connections.
  • The CAN bus is isolated (it is not referenced to the supply ground)
  • Normally it is not necessary to connect the CAN ground
  • If the master is at the end of the CAN bus, terminate the bus by connecting the each CAN line to one of the TERM lines.
back to topUSB port

Connect a USB mini-B cable to this port and to a computer running the Lithiumate GUI application.  

back to topBanks

The battery pack should be divided into between 1 and 8 banks or at least 3 cells each.
A cell board is mounted on each cell.
The two end boards in each bank are connected to the control connector. The Master sends data to the cell boards ("TX") and receives back data ("RX").
Name Type Function Wire color Notes
TX Out Transmit out Red To most positive cell in the bank
GND Gnd TX return Black
Shield Common for both TX and RX - Do not terminate at other end
Gnd RX return Green To most negative cell in the bank
RX In Receive in White
 

back to topComponents

If you wish to make your own harnesses, you may use the compoents and tools listed below.
Elithion PN Description Manuf & PN
EKV3416UA 16-way plug housing JAE MX34016SF1
EKV3440UA 40-way plug housing JAE MX34040SF1
EKV3403ST 22 AWG crimp socket JAE M34S75C4F1
EKV3404ST 20 AWG crimp socket JAE M34S75C4F2
n.a. Hand crimping tool, 20 AWG JAE CT150-1-MX34
n.a. Hand crimping tool, 22 AWG JAE CT150-2-MX34
n.a. Extraction tool JAE ET-MX34-1

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© 2008~2017 Elithion™, LLC. All rights reserved, except where noted by CC mark. Page published on Apr 27 2016.
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